1999 450s foreman resurrection - Honda ATV Forum
Repair & Maintenance Having problems? Doing a rebuild? All Repair/Maintenance Discussions here.

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post #1 of 45 (permalink) Old 05-23-2019, 11:04 AM Thread Starter
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1999 450s foreman resurrection

This a restore thread,

When I first got it, rear end was seized and wouldn’t roll. Ignition wires had been hacked away. Plastics were in very rough shape. Bike was given to me by a coworker, he had lost hope on it 10 years ago.

Positives-
Freebie so not apprehensive about putting some money into it
Was able to determine it had compression and would crank and turn over
Damaged but complete
Neutral light
Sound front diff and axles
Only surface rust on frame
Mud bug wheels

Negatives-
Rear end (diff and axle stripped)
Rear brakes locked
Reverse cable rigged permanently open
Choke broken
Broken starter button assembly
Plastics wired/tied/tie-wrapped together (no cracks, just lots of tiny holes)
Not showing gear position
Front left bearing gone
Every bolt and joint is rusty and seized.
Air filter is nasty
Carb was nasty
Front lights are smashed
No ignition
Seized rusty winch
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Macarena Man, _Wilson_ and retro like this.

2016 Honda Rubicon
2015 Yamaha Grizzly 700
1999 Honda Foreman 450s
1995 Honda Fourtrax 300
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post #2 of 45 (permalink) Old 05-24-2019, 08:04 AM
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a lot of time, few 100 dollar bills, and it will live again, IF YOU DO IT RIGHT ?!..LOL.
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'89 trx350D foreman 4x4...'85 vf700c magna, '03 trx450fm foreman 4x4 , 2015 Yamaha waverunner fx cruiser ho, '08 vt750c2 shadow spirit
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post #3 of 45 (permalink) Old 05-24-2019, 08:10 AM
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before and after : 2003 trx450fm. was pretty trashed when I picked it up, it now has been restored to new condition, and the owner is one very happy camper !.
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post #4 of 45 (permalink) Old 05-24-2019, 08:47 AM Thread Starter
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Shade, I've never done a rebuild, so doing something frame up was intimidating to me. I also live in an isolated place, so shipping costs are high. However, reading through some of the builds on here, I figured I could mimic the strategy of picking away at the machine bit by bit.
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post #5 of 45 (permalink) Old 05-24-2019, 08:48 AM Thread Starter
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Quote:
Originally Posted by shadetree View Post
before and after : 2003 trx450fm. was pretty trashed when I picked it up, it now has been restored to new condition, and the owner is one very happy camper !.
Awesome work.
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post #6 of 45 (permalink) Old 05-24-2019, 08:55 AM Thread Starter
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Worked on a bunch of stuff last night

Plastics are faded bad and whoever worked on it last lost all the plastic rivets.

I have plastic rivets on order. Not sure what I’m going to do about all the tiny holes.

I used wd40 to wipe down the plastics, then this rust oleum wipe new product. It worked really nice on the black trim. The red faded parts of the plastics are still faded to pink though.
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post #7 of 45 (permalink) Old 05-24-2019, 09:00 AM Thread Starter
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I also got the front a-arms off and painted them. Left bearing is finished. The upper and lower joints are seized to the knuckles. There’s some play in them, but I think I’ll wait on convincing them to come apart to change them until I have abit more flexibility ($) . Matt-black rustoleum.
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post #8 of 45 (permalink) Old 05-24-2019, 09:44 AM
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Just take the castle nut off the upper ball joint stud, hold the upper a arm in one hand, and hit knuckle on the outside of where the ball joint goes through it. The shock should break the tapered part of the ball joint free from the knuckle and the knuckle and lower a arm will drop to the ground.

Then hold the lower a arm, hit the a-arm where the ball joint goes through it and same thing should happen, with knuckle falling to the ground.

Don't hit the ball joint studs if the ball joints are useable. You'll mushroom the stud and ruin the threaded part.

As for those little holes, I would get black zip ties and use them. That will blend it a little better and solidly hold the flares to the fenders. A heat gun might bring that pink back to red, but usually once they're faded that bad there's not much you can do.

Looks like a really nice, solid base for a project.
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post #9 of 45 (permalink) Old 05-24-2019, 11:45 AM Thread Starter
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Thanks Jeep, I’ll try hitting the knuckles again with more confidence. Once I realized they needed a lot of persuasion I kinda just reasoned away getting them apart and just painted them as an assembly. Thinking the knuckles will look nice aluminum.

Thanks for the idea of black tie wraps, old owner probably did the hack job to make them more solid. Why not right.

2016 Honda Rubicon
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1995 Honda Fourtrax 300
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post #10 of 45 (permalink) Old 05-24-2019, 11:46 AM Thread Starter
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Ps, when I fired her up odo read ~23,000km, about 14,000miles. Doesn’t smoke (yet, knock on wood)

2016 Honda Rubicon
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